DE102007004232A1 - Product e.g. primary product, manufacturing arrangement, has control device receiving actual data from detection devices and process plant by current process of products and adjusting current process to optimized process of product - Google Patents

Abstract

The arrangement (10) has a control device (12) for fine planning and optimizing a manufacture of products and arranged between a customer order data detection device (14) i.e. enterprise resource planning-device, and a process plant (16). The control device receives an actual data from the customer order data detection device, a capacity parameter detection device, a noise parameter detection device and the plant by a current manufacturing process of the products. The control device adjusts the current process to an optimized manufacturing process of the products. An independent claim is also included for a method for time and quantity and/or throughput optimized manufacturing of a product.

Description

The The invention relates to an arrangement and a method for time and Volume or throughput optimized production of at least one product from at least one raw material and / or intermediate by means of process engineering Attachments.

arrangements and methods for time and volume or throughput optimized production of so-called piece goods are well known. In the general cargo production will be the specifications for the Production of a product in the form of a piece goods with parts lists and work plans described. Due to the nature and nature of such cargo let yourself the general cargo production readily interrupt and postpone, if that for example, due to unforeseen changes in the order situation, such as preferable express orders, or unforeseen occurrence of disturbances would be required.

Different behave it is, however, in the production of products by means of process engineering processes and facilities. An interruption and a time shift is in usually already due to thermal and / or chemical reactions of raw materials, auxiliaries and substances to be used or of precursors, intermediates and ultimately also products with each other during the procedural processes excluded. When manufacturing processes to start depends on other of deadlines of the customers (delivery dates), the duration the plant usage (shift times) and the speed, in of the products can be reproduced (lead time).

The Production of at least one product from at least one raw material and / or intermediate designed by means of process engineering equipment Therefore, much more expensive than the production of a piece goods and requires the greatest accuracy and foresight in the planning of it.

in the Generally, the planning is shared by the whole process Production of a product in a so-called "rough planning" and a so-called "detailed planning" on.

The Rough planning includes 1) the assignment of customer or warehouse orders to parts lists, Formulations of premixes, precursors, intermediates, etc., Work plans, production-specific (sub-) processes, etc., monitoring of the goods receipt, examinations, Quality control, Bookings, Feeder of the delivered materials, etc. to the intermediate storage depots and Storage locations, control and monitoring a removal and / or reordering of itself already in the interim storage and storage locations located materials, raw materials and the Provision for planned production processes, 2) the determination of own or materials manufactured by third parties, raw materials, premixes, Precursors, intermediates, etc. with quantity and delivery date and 3) the procurement of materials, raw materials, components, premixes, Intermediate products, intermediates, etc. in suitable quantities (order quantities, externally or internally produced). Known method of rough planning check hence the availability of components, raw materials and materials and give as appropriate an appointment estimate with start of the manufacturing process. In the rough planning will be in general also subsequent deliveries of materials, raw materials etc. treated. The rough planning, like the entire material management, Ordering of components, raw materials and supplies, accounting stored and ordered quantities, specification of requested delivery dates, deadline monitoring etc., usually takes place by means of commercially available commercial Systems, so-called Enterprise Resource Planning (ERP) systems. About that In addition, in such systems, the parts lists, Recipes, etc. for the products deposited. However, the rough planning is neither determined still suitable, about it Further planning, such as optimal occupancy of the facilities or an optimal time for to make a specific investment. ERP systems are also unsuitable because they have a process throughout Map process time, d. H. without plant-specific differentiation. are for the assignments required materials, raw materials, components, etc. in the desired Quantities are available, these are usually order-specific in the ERP system Reserved and recorded accordingly. Orders, which due to lack of resources make a production run impossible, are sorted out. The rough planning is thus a purely control technology Process that only represents part of the production planning and not least because of this for the increasingly important, further part of the production planning in the form of a detailed planning certainly, let alone such a make.

On the other hand, the detailed planning, which follows the rough planning, consists of 1) the planning of the sequence of (partial) production processes and processes, 2) the scheduling of the use of the required equipment, machines, personnel and others for the manufacturing processes necessary resources, such as energy, supplies and equipment (asset allocation planning), whereby the beginning of the use depends significantly on the deadlines of the customers (delivery dates), the duration of the plant use (shift times) and the speed of manufacturing the products (lead time) , 3) the execution of individual production steps te ("actual production") according to the work plan or work instruction; and 4) the allocation and summary of order quantities for plant-specific production quantities.

With Help the experience, the company employees with the Manufacturing processes have forecast data, order template, expected Orders etc. are the time duration for the work processes, resources that can not be fixed in rough planning, the use of for the manufacturing steps suitable machinery, equipment and tools etc. set. At times, the one specified in the detailed planning is also used temporal allocation of the plants, machines, manual processes in a production plan with the help of visualization systems, such as For example, pegboards or magnetic boards, detained. The detailed planning is the basis for the production for which Use and operation of the equipment by the staff, for internal Stock movements, transport processes, Provision of precursors and / or intermediates, etc., Specifications for Interim storage facilities, filling and packaging processes, etc. For Manufacturing processes, which are repeated on the same equipment or machines, The detailed planning is easy to set. As the manufacturing processes and Repeat processes, there is sufficient experience to one Create fine planning with high accuracy. Stand against it different production facilities for the same production process available the planning of production processes complex. To have to the expected terms of the equipment producing for different orders estimated in time and new orders be fit in the course of the shift on schedule. Another one Problem is that the production times by sampling and associated production interruptions, replenishment etc. are not, at least not sufficiently accurately planable. Corresponding The provision of materials, raw materials, etc. should also be specified. If manufacturing processes run in multiple stages or different Machinery and equipment for manufacturing can be used, precursors have only certain shelf life (chemistry, food) chaining between individual (sub-) processes are necessary, production planning very extensive and is no longer easy to perform. Corresponding elaborate is the detailed planning. Because production plans point into the future (forecasts) and complex processes with all the details in only a few phases A detailed representation of a manufacturing process is today's Detailed planning accordingly inadequate.

The Detailed planning becomes even more complicated when disruptions or short-term changes appear in the order book and existing plans need to be modified. Disruptions can cause Example failures of equipment due to technical defects. But also inadequate quality of raw materials, materials, assemblies, precursors, failure of Personnel due to illness or vacation, intervening or im Appointment changed assignments at the request of customers, longer Production times due to additional quality assurance Activities, Reworking, over time varying chemical Reactions etc. bring the production plan, mostly for some Days is set, confused. Often, coarse and fine schedules are then to recreate. Because such disturbances correct under time pressure, the correction is accordingly superficial. Furthermore, the accounting of the materials, their reordering etc. already completed in rough planning. The changes to lead to reduce the effective manufacturing time and thereby increase Production costs.

Be solved such stochastic and temporally unpredictable problems today with short-term discussions of the production process involved personnel. It is often after fast, however poorly thought-out solutions sought. The effects of changes made are mostly not sufficiently transparent and predictable. The quality of the detailed planning is therefore deficient.

A changed so At the same time, detailed planning has a considerable influence on previous ones or the following, already planned manufacturing processes. Will for example a product, an assembly, a preliminary product is postponed produced, has an effect on the temporal use of the resources required for this, such as materials, raw materials or personnel, for all subsequent processes. Also the use of resources, initially not directly the production process such as transport, quality assurance measures, prepare and cleaning of equipment etc. are covered by the changes or faults. modification the original one Therefore, plans usually extend Production times, employees need increased benefits provide. Modified procedures thus require an additional Planning effort and, in turn, an increased cost.

One Another problem of production planning in the form of detailed planning lies in the accuracy of the time specifications. This can significantly increase production times fluctuate if, for example, the planned production time by conversions of plants and machines, different process times in chemical Reactions or increased effort for quality assurance extended.

The problems mentioned get worse In recent years, customers' average order volumes are falling. Customers pay attention to reduced storage costs due to storage costs. The consequences are shorter order cycles and smaller order quantities and shorter reaction and lead times to meet customers' deadline requests. Frequent product changes in turn make the throughput times longer and at the same time increase the planning effort. In addition, a stronger diversification of the assortment leads to a complex detailed planning. Extreme demands on delivery dates, short lead times and associated production schedules exist when customers demand "just-in-time" delivery, which means that suppliers' manufacturing processes must be interlinked with their own production processes. The detailed planning is then limited to very short times and increasingly requires improvisation.

It An attempt is made to solve these problems of detailed planning with the help of so-called "reserve times", as well as so-called "safety stocks" of disguised material inventories and as "reactive power", from increased in the first place Provision of personnel and reduce plant capacity. The problem the poor quality but this is not eliminated in the detailed planning.

On the detailed planning finally follows the fine planning often yet to be allocated planning for the Picking of manufactured products, internal and external Transport, storage and retrieval, shipping, etc.

Known Arrangements and methods for the Detailed planning of the production of at least one product from at least a raw material and / or intermediate by means of process engineering Facilities exist, but are all based on one control technology and thus static, linear operation. These arrangements and methods for fine planning possess therefore all the serious disadvantage of not being able to find a suitable one propose alternative production plan and thus flexible and individually on unplanned events in the production of at least a product, such as an unforeseen change order situation, such as urgent urgent orders, or unforeseen occurrences of disorders to be able to react. Yet another, essential problem arises from that's possible Disadvantages and / or consequences of mostly short-term planning changes occur, such as costs, relocation of assigned orders, etc., not to estimate in advance or recognize. Try other arrangements and procedures to counter this malady with probability calculations. Of the Effort for Data entry and data maintenance is extremely expensive, uneconomical and not practical.

Of the Invention is therefore based on the object, an arrangement and a Process for time and volume or throughput optimized production at least a product of at least one raw material and / or intermediate to provide by means of process engineering facilities, with which can prevent the above disadvantages, which therefore constructive particularly simple, fast, with high accuracy and at the same time reliable one Detailed planning of complex, multi-stage process engineering processes with a variety of raw materials, precursors, intermediates etc., thereby shorten and accelerate the process engineering processes as well as additionally very inexpensive are.

These Task is in device-technical terms to surprising simple manner solved by the features of claim 1.

By the inventive design of the inventive arrangement for time and volume or throughput optimized production of at least one product from at least one raw material and / or intermediate and / or intermediate product by means of process engineering equipment comprising a control device for fine planning and optimization of the production of at least one product, the control device being arranged between a customer order data acquisition and delivery device and the interactive communication processing systems, comprising means for acquiring and providing capacity parameters and means for acquiring and providing disturbance parameters, if disruptive parameters are (already) present and / or unpredictably occur (in the meantime or subsequently), by the facility for recording and delivering customer traffic to obtain data on the actual production process of the at least one product, to desired data or planning data of a production sequence of the at least one product in Depending on the minimum required time and / or the maximum producible amount / throughput of the at least one product processed and adapts the current production process to the optimized production process of at least one product is a structurally particularly simple, also directly responsive and thus fast-working arrangement as a whole reached. At the same time with the inventive arrangement a high accuracy in the detailed planning and optimization guaranteed. In addition, a wide variety of planning variants can be compared, saved and evaluated in real time. Of particular importance in all that the arrangement comprises a control device for fine planning and optimization of the production of at least one product, which is arranged between the device for recording and delivery of customer order data and the process engineering facilities, which significantly reduces manufacturing processes and thereby the Making products more efficient. Along with this, on-schedule planning of individual production stages and intermediate products and / or intermediate products as well as occupancy of the installations, including the occupancy times that are necessary to execute production orders on time, can be achieved in a simple and extremely exact manner. Not least as a result, products manufactured using any process engineering production technique, including recipe-specific manufacturing ("step-by-step" manufacturing), can be produced with shorter lead times and better utilization of manufacturing capacity. The control device thereby lowers production costs. Investments in facilities that were made as before to "be on the safe side" and only in a few and very limited time windows to reduce production peaks, can be omitted. Stock costs for raw materials, primary products, intermediate products and (finished products) are also reduced due to faster post-production and improved inventory management.

All particularly advantageous structural details of the arrangement according to the invention for time and volume or throughput optimized production at least a product of at least one raw material and / or intermediate by means of process engineering systems are in the claims 2 to 10 described.

Of Furthermore, this task is surprising in terms of process engineering simple manner solved by the features of claim 11.

• a) Erfassen von Kundenauftragsdaten durch eine Einrichtung zur Erfassung und Lieferung bzw. Bereitstellung von Kundenauftragsdaten,
• b) Liefern der Kundenauftragsdaten durch die Einrichtung zur Erfassung und Lieferung von Kundenauftragsdaten an eine Regelungsvorrichtung,
• c) (Interaktives) Kommunizieren zwischen der Regelungsvorrichtung und der Einrichtung zur Erfassung und Lieferung von Kundenauftragsdaten sowie den verfahrenstechnischen Anlagen,
• d) Erfassen von Kapazitätsparametern durch eine Einrichtung zur Erfassung und Lieferung bzw. Bereitstellung von Kapazitätsparametern und Liefern bzw. Bereitstellen von Ist-Daten über den aktuellen Herstellungsablauf des wenigstens einen Produktes an die Regelungsvorrichtung,
• e) Erfassen von Störparametern durch eine Einrichtung zur Erfassung und Lieferung bzw. Bereitstellung von Störparametern und Liefern bzw. Bereitstellen von Ist-Daten über den aktuellen Herstellungsablauf des wenigstens einen Produktes an die Regelungsvorrichtung, sofern Störparameter (schon) vorhanden sind und/oder unvorhergesehenermaßen (zwischenzeitlich bzw. nachträglich) auftreten,
• f) Verarbeiten der von der Einrichtung zur Erfassung und Lieferung von Kundenauftragsdaten, der Einrichtung zur Erfassung und Lieferung der Kapazitätsparameter, der Einrichtung zur Erfassung und Lieferung von Störparametern sowie den verfahrenstechnischen Anlagen erhaltenen Ist-Daten über den aktu ellen Herstellungsablauf des wenigstens einen Produktes zu Soll-Daten bzw. Plandaten eines Herstellungsablaufs des wenigstens einen Produktes in Abhängigkeit der minimal erforderlichen Zeit und/oder des/der maximal herstellbaren Menge/Durchsatzes des wenigstens einen Produktes, und
• g) Anpassen des aktuellen Herstellungsablaufes an den optimierten Herstellungsablauf des wenigstens einen Produktes durch die Regelungsvorrichtung,

ein konstruktiv besonders einfaches Verfahren zur Produktionsplanung und speziell Feinplanung anstelle eines steuerungstechnischen, statischen Prozesses, der bestimmte Festlegungen für eine definierte Zeitperiode macht, als regelungstechnischer, dynamischer Prozess, ohne zeitliche Begrenzung vorgesehen. Insbesondere ist die Feinplanung als Regelung ausgestaltet, die dynamisches Verhalten zeigt, d. h. dass auf Störungen, wie Änderungen von Kundenaufträgen, Mangel an Ressourcen, Störungen der Anlagenverfügbarkeit usw., sofort reagiert und alternative Vorschläge unterbreitet.Accordingly, by the embodiment of the method according to the invention for time and volume or throughput-optimized production of at least one product from at least one raw material and / or intermediate and / or intermediate product by means of process engineering plants, comprising the following steps:

• a) collecting customer order data by a device for the acquisition and delivery of customer order data,
• b) supplying the customer order data by the means for acquiring and delivering customer order data to a control device,
• c) (Interactive) communication between the control device and the device for collecting and delivering customer order data and the process engineering systems,
• d) detecting capacity parameters by a device for detecting and supplying or providing capacity parameters and providing actual data about the current production sequence of the at least one product to the control device,
• e) detecting interference parameters by a device for detecting and delivering or providing interference parameters and delivering or providing actual data on the current production sequence of the at least one product to the control device, if disturbing parameters are (already) present and / or unforeseen ( in the meantime or subsequently),
• (f) processing the actual data on the current production sequence of the at least one product at target obtained by the customer order data collection and delivery device, the capacity parameter acquisition and delivery device, and the process engineering equipment Data or planning data of a production sequence of the at least one product as a function of the minimum required time and / or the maximum producible amount / throughput of the at least one product, and
• g) adapting the current production sequence to the optimized production sequence of the at least one product by the control device,

a structurally particularly simple process for production planning and especially fine planning instead of a control-technical, static process, which makes certain determinations for a defined period of time, as a control-technical, dynamic process, provided without time limit. In particular, the detailed scheduling is designed as a scheme that shows dynamic behavior, ie that respond immediately to disruptions such as changes in customer orders, lack of resources, disruptions in plant availability, etc. and makes alternative proposals.

From Of particular importance are the features of claims 12 and / or 13, according to which one or more suitable plant / s from the disposal standing plant / s depending on the minimum required time and / or the maximum manufacturable Quantity / throughput of the at least product for controlled detailed planning selected retrograde will be.

Other particularly advantageous individual units of the process according to the invention for the time and volume or throughput-optimized production of at least one product from at least one raw material and / or intermediate product by means of process engineering plants are described in claims 14 to 47.

Further Advantages, features and details of the invention will become apparent the following description of a preferred embodiment of Invention and with reference to the drawings. Hereby show:

1 2 a schematic representation of an embodiment of an arrangement designed according to the invention for the time and volume or throughput-optimized production of at least one product from at least one raw material and / or intermediate product by means of process engineering systems,

2 a schematic representation of the embodiment of the invention designed according to the arrangement 1 in an enlarged view,

3 a schematic representation of the embodiment of the invention designed according to the arrangement 2 , in an enlarged view, and

4 a schematic representation of an embodiment of a known arrangement for time and volume or throughput optimized production of at least one product of at least one raw material and / or intermediate product by means of process engineering equipment.

In the following description of an embodiment of the inventive arrangement 10 are corresponding to each other, the same components each provided with identical reference numerals.

The order 10 according to the invention and / or the method according to the invention is / are for time and volume or throughput optimized production of at least one product from at least one raw material and / or intermediate and / or intermediate product by means of process engineering facilities provided.

In the in the 1 to 3 illustrated embodiment, the inventive arrangement 10 a control device 12 , The control device 12 is intended for detailed planning and optimization of the production of the at least one (finished) product.

The control device 12 is between a facility 14 for the collection and delivery or provision of customer order data and process engineering systems 16 arranged. The control device 12 , the device 14 for the collection and delivery of customer order data and the process plants 16 are connected to each other or assigned to each other such that between the control device 12 and the facility 14 on the one hand and the process engineering plants on the other 16 On the other hand, at any time an interactive and continuous communication in the bidirectional direction according to the arrows 18 . 18 ' respectively. 20 . 20 ' can take place. Although such interactive and constant communication is not necessarily required in a (initial and / or new) planning under certain circumstances, it is in any case following a so-called monitoring in one of the (initial and / or new) planning (Follow-up) planning during / the running process / s required. Without being shown in detail, is between the control device 12 , the device 14 and the process plants 16 also any other direction of communication) with each other possible.

As in particular from the 2 and 3 shows, is the control device 12 continuing with a facility 22 for recording and delivery or provision of capacity parameters of the process plants 16 , Intermediate storage locations and storage locations as well as filling or packaging plants, the at least one raw material and / or intermediate product and / or intermediate and the staff connected. Input data for the control device 12 are sales orders that are transcoded to company-internal codes, such as order numbers, bills of material, recipes, filling specifications, container sizes, transport regulations, etc., thus enabling a clear assignment between the sales order and the associated processes and input materials. Capacity parameters of which the control device 12 are material and raw material stocks, stocks of preliminary and intermediate products, the presence and the current availability of production facilities 16 , Machinery, components, interim storage facilities, storage facilities, filling and packaging facilities and the personnel and / or personnel resources available in the enterprise are necessary for the manufacture of the products and are currently or in the short and medium term available. All operational resources of the company are thus represented by these capacity parameters. Other capacity parameters may include plant equipment data, throughput, capacity, speeds such as filling and packaging rates, fill levels per time, networking with other equipment 16 , Transport routes, bearing coordinates for materials or path components for the feeding or weighing of Raw materials, intermediate products, intermediates, cleaning and set-up personnel, and much more.

In addition, the control device 12 preferably with a device 24 connected to the detection and delivery or provision of interference parameters or is the control device 12 such a device 24 assigned. Disturbance parameters can include, for example, disturbance variables such as system failure, faulty or missing components, assemblies and components of the individual process plants 16 , missing or not prepared timely intermediate products and / or intermediate products, raw material or material defects, missing operating or transport personnel, insufficient or missing transport options, interim or changed orders, such as interposed customer orders, deadline and quantity changes, etc., be. The device 24 for detection and delivery of interference parameters can be used according to the invention optionally. This depends essentially on whether, for example, disturbance parameters (already) are present and / or occur unforeseen (in the meantime or subsequently). In addition, on an employment of such a device 24 Under certain circumstances, for example, when playing in a (initial) planning, be waived, as can generally be assumed that the current state of the process plants 16 is sufficiently determinable at the time of planning or detailed planning on the basis of the capacity parameters. If this is not the case, such a facility would come 24 however, for use. In contrast, such a device 24 at least in the case of so-called monitoring, that is to say in the case of continuous monitoring, during the ongoing process (s) of particular advantage.

Operating data, from machines, plants 16 , Measurements, quality data, but also shift times, calendar specifics, such as holidays, are influencing variables that the control device 12 additionally considered.

The control device 12 Processes the actual data provided by the facility 14 for the collection and delivery of customer order data, from the facility 22 to collect and deliver the capacity parameters and facility 24 for the collection and delivery of disturbance parameters as well as the process engineering plants 16 and reproduce the current production process of the at least one product to desired data or plan data of a production sequence of the at least one product. The processing of the actual data by the control device 12 may in this context can be timely or largely timely upon receipt. Alternatively or cumulatively, the processing of the actual data can also take place with a time delay. In this case, the actual data is first stored in a memory or the like module (not shown), which, for example, the control device 12 is assigned, collected and / or stored and the control device 12 timed, ie after specified time intervals, and / or event-oriented, ie depending on the priority or meaning of an event, fed to their processing.

The desired data are created depending on the minimum time and / or the maximum producible amount / throughput of the at least one product. Target data may be based on constraints such as minimum lead times, minimum power consumption, specific mass throughput, minimum production cost, minimum material consumption, or minimal (single and / or total) costs. Finally, the control device fits 12 Based on the obtained target data, the current production process to the optimized production process of the at least one product in real time.

Preferably, the control device 12 like that 1 and 2 is removable, for this purpose with the device 14 for the collection and delivery of customer order data and the process plants 16 via separate coupling devices 26 . 28 connectable. The separate coupling devices 26 . 28 act as an interface. The interfaces can work permanently and / or event-oriented or event-dependent.

The coupling device 26 It has the task of order data, customer names, delivery dates, filling, packaging, packaging shipping and transport instructions, specifications for (intermediate) storage, as well as other order-related data from the facility 14 for the acquisition and delivery of customer order data to take over, prepare data technology and the control device 12 to provide. A transfer of the data can be effected, for example, via bus systems (not shown), for example Ethernet or Profibus bus systems.

The coupling device 28 on the other hand, processes data that the process engineering systems 16 or generate control systems and the control device 12 to hand over. As a result, the control technology function can be achieved in the sense of minimizing the deviation between the plan or target data and the actual data. The coupling device 28 can also monitor functions, ie a representation of the actual state of running systems 16 and machines, take over. A transfer of the data can, for example, via bus systems (not shown), for example Ethernet or professional bus bus systems.

According to the 1 to 3 is the control device 12 with the device 14 for the collection and delivery of customer order data and the process plants 16 connected to each other for interactive or mutual communication.

The device 14 for the acquisition and delivery of customer order data can be exemplified as Enterprise Resource Planning (ERP) device or the like system.

The device 22 for the acquisition and delivery of capacity parameters of process plants 16 Intermediate storage locations and storage locations as well as filling or packaging installations and of the at least one raw material and / or intermediate product and / or intermediate product and of the personnel can also be embodied according to the invention at least in part as an Enterprise Resource Planning (ERP) facility or similar system. Without going further in detail, it is also conceivable according to the invention, the device 22 for the capture and delivery of capacity parameters at least partly also directly in an enterprise resource planning (ERP) device or the like system to consider or integrate.

The device 14 to collect and deliver customer order data and the facility 22 for the acquisition and delivery of capacity parameters each communicate with the device 24 for recording and delivery of disturbance parameters.

Furthermore, the process engineering systems communicate 16 with the device 14 for entering and delivering sales order data.

The control device 12 With this, the entire process chain from order intake or customer order to the delivery of the required services is represented. By simulating the possible control processes with different capacity parameters and disturbance parameters, the best situation-specific plan is displayed. In this case, the control device comprises 12 An institution 30 to optimize the entire processes and manufacturing processes including a recipe-specific or "step-by-step" production in order to optimally regulate multi-stage production processes. As a result, different, situation-based solution proposals by the control device 12 determined and collected first. The best solution, for example, with minimal lead time for an entire manufacturing process, is then displayed on a suitable visualization device or the like.

For this purpose, the control device comprises 12 An institution 32 for visual presentation and evaluation of the actual data and / or desired data of the production sequence of the at least one product. The display can be done in different ways: As a GANTT diagram for visualizing the occupancy of the necessary for the production of orders installations over time both as a planning tool and a real-time message, as a bar chart to indicate the bottleneck situation, for example, the lack of raw materials, plant capacities , human resources, etc., as a production plan for the operator with specification of the time schedule, the materials to be procured or provided, raw materials, components, precursors, assembly, etc., or as a list showing all the problems that may arise in future manufacturing, such as raw material shortage, equipment overload, capacity bottleneck, etc.

The peculiarity of the arrangement according to the invention 10 This is because a new optimized production plan can be generated at any time and at every event. The production plan shows the use of resources over time with possible bottlenecks on the visualization system. The staff can change the plan and activate it. The events are adjusted.

The control device 12 Data from the production process are continuously fed in as actual data. The detection takes place via the peripheral devices.

Alternatively, the control device 12 An institution 34 for manual entry of customer order data and / or capacity parameters and / or disturbance parameters, which is to be operated by the staff. These can be run times of systems with start and stop commands, measured values, weighing data, fill levels, target values and other physical or chemical parameters. This data is processed by the control device 12 so that deviations between that in the control device 12 produced production plan (ex ante) are compared to the real process in the production process (ex post). Since there is a time interval between planning and realization of the production plan, the control device has 12 a device for storing data and information (not shown) in order to be able to make a comparison between the actual data and the desired data or planning data in due course.

As the control device 12 Also includes a means for optimization, which includes a Carries out optimization calculation, it is ensured that the control device 12 always produces the production plan with the production processes that result in the shortest turnaround times or other best-looking solutions.

Finally, below is an example for processing an order for producing at least one product by means of an arrangement 10 according to the invention explained in more detail: First, a planning period is set in which the planning of the production orders should run. Sundays and holidays are automatically included in the plan.

thereupon the number of shifts and the duration of a shift should be defined, also possible overtime to take into account are.

The order 10 According to the invention, within the planning period, all recipes or partial formulations and intermediate products, intermediate products and (finished or end) products belonging to the production orders of the planning period are searched for. Quantities of identical formulations for precursors, intermediates and (finished or end) products are summed up in order to obtain the largest possible production quantities with the same formulations within the planning period. Blocked products or recipes and merchandise are sorted out.

The order 10 searches for the delivery date of the first product to be delivered at the earliest point in the plan period. The requested delivery date is specified by the sales order. This first production order is assigned the associated recipe.

The order 10 checks whether the materials for this recipe are available in sufficient quantities. If resources are missing, the arrangement looks for 10 the date on which the materials are available in sufficient quantities. The order 10 moves this production order to this production date and displays the problems. If the production date is postponed, the remaining materials that are necessary for the production process are released again, ie they can be used for other orders.

The order 10 checks if all other restrictions, such as maturities of investments 16 or staff, etc., and may determine a new appointment. The request date for the production order is postponed to the date on which the production can be started without any problems. If a production order can not be made on the requested date, the arrangement shifts 10 the order on the next possible date and tries to schedule the precursors accordingly. If a manufacturing process may be interrupted, the control device checks 12 whether at least partial production within the shift is possible. If this is the case, the final production can be resumed in a subsequent history.

The order 10 chooses the suitable production equipment 16 which are approved for the first production order.

The piping between the plants 16 as well as other conditions, for example required heaters, stirrer speeds, etc., are checked for the first production order. The order 10 sorts the plants 16 which do not allow production of the recipe or are blocked within the planning period.

The order 10 considers the chronological order of the preliminary products in the production sequence and registers the offset time for intermediate products.

For the last production step of an end product of the first production order is from the group of admissible systems 16 a suitable facility 16 For example, a bottling plant, or for the first to be produced intermediate the last plant 16 in the process chain.

The default occupation time for a plant 16 Determines the time required for the entire manufacturing process on this plant 16 is required. The plant-specific standard occupancy time or the duration of the manufacturing process is specified in the recipe.

The attachment 16 which, taking into account the standard occupancy time, has the shortest interim storage time between the last production step, for example between the filling process and the preceding production step, is selected. This allows the latest start time of this system 16 and calculate for this intermediate or final product manufacturing step.

For all suitable systems 16 For this production step the latest start times have to be calculated.

Of the The process is to be repeated, with the set-up and cleaning time added together become. If a plant configuration has shorter lead times, then this favors.

The Previous 8 steps are for the previous attachment in to repeat the process sequence.

The The process continues until all production stages of a Intermediate or finished product are processed. It arises for each Production order process chains with minimal lead times and spätesten Start times for the production of intermediates and end products.

Are plants 16 For the production of intermediates or final products selected for a production order, it is necessary to check whether the equipment 16 already occupied by preceding production processes and how long the plants are 16 still in operation. These assignment times increase the times for a production sequence, ie the processing of an order.

Taking into account current equipment 16 is again to determine which manufacturing sequence is the shortest.

For subsets of the total, alternative solutions must be determined so that the subsets into other assets 16 fit. Splitting or splitting or summarizing orders can be made. Partial quantities can be produced in parallel in the same system in succession or in different systems. The shortest lead time determines the selection. This also applies to intermediates.

If interim storage times arise between individual production stages, because the successive production processes have, for example, different standard occupation times and can not be directly produced one after the other, this is due to the arrangement 10 to look for an interim storage facility.

It must be checked whether a product with intermediate storage can be manufactured in the plant with a shorter cycle time, whereby the plant 16 is no longer needed in the storage period, or in a special storage location, such as a tank, big bag, storage space, etc., can be stored. When stored elsewhere, the transport times, such as pumping times, piping, cleaning times of the storage facilities, as it were to be considered.

It must be indicated where and when the intermediate storage is planned. The setup and cleaning times must be taken into account during intermediate storage. Regardless of this, temporary storage may also be provided in the installation (s) 16 be done, which, however, this is in turn assigned a waiting time / will.

A filling or packaging may be from the manufacturing plant or from an intermediate storage respectively. Decision criterion are plant utilization, existing ones Human resources (operating personnel) and lead time.

The optimal container filling is determined by the capacity of a system 16 in discontinuous processes or batch processes, for example, by adding up the multiple bottoms, or the throughput per time in continuous processes tested. It will be the plant 16 which has the least empty capacity in discontinuous processes or the lowest standstill time in continuous processes.

As well can in a production order a continuous production without intermediate storage and without summarizing like batches.

Production orders can do so be fixed in the planning that in each case the requested delivery date is complied with.

If, by dividing a production quantity, a difference amount smaller than the sum of the sumps remains, this indicates the arrangement 10 at. A decision is made as to whether this difference quantity should continue to be planned or discarded.

If a shift is not busy, the device will check 10 Whether production orders, intermediate orders, etc. can be brought forward within the planning period. In other words, an attempt is made to fill the still available time of a shift with advanced production (sub) processes. The production orders and appointment changes are displayed. The associated (intermediate) storage facility is taken into account.

It can also production orders outside be preferred to the planning period.

The order 10 considers collective deliveries, whereby the most recent product of a collective delivery for the remaining start and end times of the products from the collective delivery is decisive.

The order 10 takes into account all the production processes already started in a new planning run, so that all related batches, intermediate products, intermediate products that have already been started are "frozen" and taken into account in the next or one of the subsequent planning / s.

Each plan can be saved, compared to other plans, and retrieved later. There may be different planning periods to be planned. Changes in the planning can be displayed after each planning run. A comparison between old and new plan is possible at any time.

The occupancy of the plants 16 is determined by means of a GANTT diagram by means of the device 32 presented for visualization. The same applies to the duration of each batch, which batches are merged or cascaded and which process is expected to expire. Intermediate cleaning and final cleaning are displayed with the duration.

In addition, in the production plan, the time allocation of the systems 16 in the course of the shift, the corresponding recipes, substances to be entered, etc. are displayed.

If requested delivery dates can not be met, this shows the order 10 with the new appointment. Also on batches, plants, raw materials, etc. is pointed out, which cause the delivery problems. In the case of missing raw materials, the shortages and, if there are no plant run times, the absenteeism of the relevant plants are determined.

manual Interventions in the GATT diagram are by drag and drop in the frame shift times and restrictions allowed. Limits of these interventions are shown. The associated Production plan is changed.

One Raw material shortage can be reported to the procurement or triggers automatic Purchase orders out.

amendments deadlines, product quantities, system run times including overtime of the staff are allowed by entering new values. By change of raw material quantities etc. and system running times, delivery dates can be corrected.

The Query the storage situation, d. H. Finished and raw material warehouse, is possible. asset history can be displayed over time.

The utilization of the plants 16 is possible over time.

Based on the terms of the systems 16 , the type of equipment 16 , the raw material quantities and from the recipe, the production costs can be calculated. Balanced with the revenues of a product, the contribution margin of a product can be determined. For the plan period, it is also possible to determine the total contribution margins of individual orders.

By Comparison of two planning variants can be different production scenarios are processed.

Become Data from production fed back into the planning system, So-called monitoring, can actual data and target data or Compare plan data, possibly existing deviations simply and quickly recognize and thus finally one at the current time receive and select optimal detailed planning.

Claims (47)

Arrangement for time and volume or throughput-optimized production of at least one product from at least one raw material and / or intermediate product and / or intermediate product by means of process engineering systems, comprising a control device ( 12 ) for fine planning and optimization of the production of the at least one product, wherein the control device ( 12 ) between a body ( 14 ) for the collection and delivery of customer order data and the process plants ( 16 ) is arranged for interactive communication, with a device ( 22 ) for the collection and delivery of capacity parameters and a facility ( 24 ) is connected to the collection and delivery of disturbance 14 ) for the collection and delivery of customer order data, the facility for the collection and delivery of capacity parameters, the facility ( 24 ) for the collection and delivery of the disturbance parameters and the process plants ( 16 ) Actual data on the current production process of the at least one product receives, processed to desired data of a manufacturing process of the at least one product depending on the minimum time required and / or / the maximum producible amount / throughput of the at least one product and the current manufacturing process Adjusts to the optimized production process of at least one product. Arrangement according to claim 1, characterized in that the control device ( 12 ) with the device ( 14 ) for the collection and delivery of customer order data and the process plants ( 16 ) via separate coupling devices ( 26 . 28 ) is connectable. Arrangement according to claim 1 or 2, characterized in that the control device ( 12 ) with the device ( 14 ) for the collection and delivery of customer order data and the process plants ( 16 ) is connected to each other for interactive communication. Arrangement according to one of claims 1 to 3, characterized in that device ( 14 ) to Capture and delivery of customer order data is designed as Enterprise Resource Planning (ERP) device or similar system. Arrangement according to one of claims 1 to 4, characterized in that the device ( 22 ) for recording and supplying capacity parameters of the process plants ( 16 ), Intermediate storage and storage facilities and bottling or packaging and at least one raw material and / or intermediate and personnel at least partially as Enterprise Resource Planning (ERP) device or the like system is formed. Arrangement according to one of claims 1 to 5, characterized in that the device ( 14 ) for the collection and delivery of customer order data and the facility ( 22 ) for the collection and delivery of capacity parameters each with the facility ( 24 ) communicate for the collection and delivery of disturbance parameters. Arrangement according to one of claims 1 to 6, characterized in that the procedural systems ( 16 ) with the device ( 14 ) communicate to collect and deliver sales order data. Arrangement according to one of claims 1 to 7, characterized in that the control device ( 12 ) An institution ( 30 ) for optimization. Arrangement according to one of claims 1 to 8, characterized in that the control device ( 12 ) An institution ( 32 ) for the visual presentation and evaluation of the actual data and / or desired data of the production process of at least one product. Arrangement according to one of claims 1 to 9, characterized in that the control device ( 12 ) An institution ( 34 ) for manual entry of customer order data and / or capacity parameters and / or disturbance parameters. Method for time and volume or throughput-optimized production of at least one product from at least one raw material and / or intermediate product by means of process engineering systems, in particular according to one of claims 1 to 10, comprising the following steps: a) acquisition of customer order data by a device ( 14 ) for the collection and delivery of customer order data, b) the delivery of customer order data by the facility ( 14 ) for collecting and delivering customer order data to a control device ( 12 ), c) communicating between the control device ( 12 ) and the institution ( 14 ) for the collection and delivery of customer order data as well as the process engineering systems ( 16 ), d) detecting capacity parameters by means ( 22 ) for the acquisition and delivery of capacity parameters and delivery of actual data on the current production sequence of the at least one product to the control device ( 12 ), e) detecting disturbance parameters by means ( 24 ) for the detection and delivery of disturbance parameters and delivery of actual data about the current production sequence of the at least one product to the control device ( 12 ), f) processing by the institution ( 14 ) for the collection and delivery of customer order data, the facility for the collection and delivery of capacity parameters, the facility ( 24 ) for the collection and delivery of interfering parameters and the process plants ( 16 ) obtained actual data about the current production process of the at least one product to target data of a production process of the at least one product depending on the minimum required time and / or the maximum producible amount / throughput of the at least one product, and g) adjusting the current manufacturing process to the optimized production sequence of at least one product by the control device ( 12 ). Method according to claim 11, comprising the following steps: a) determining the required equipment (s) of the at least two stages (n, n-1), b) determining the available equipment (s) of stage (s), c) comparing the required equipment Annex (s) corresponding to step (a) and the available plant (s) of step (s) corresponding to step (b), d) selecting one or more suitable plants from the available plant (s) n the stage (s) corresponding to step b), e) determining the available equipment (s) of the preceding stage (n-1) in dependence on the selected suitable equipment (s) of stage (s) corresponding to step d), f ) Comparing the required equipment (s) of stage (n-1) corresponding to step a) and the available equipment (s) of the preceding stage (n-1) according to step e), g) selecting one or more suitable equipment (s) from the available installation (s) (n - 1) according to step f) or g) depending on the minimum required time and / or the maximum producible amount / flow rate of the at least product, and h) repeating steps e) to g) for each further of the step (n - 1) previous stage (n - 1 - x) with x = 1 ... ∞. Method according to claim 12, characterized in that that one or more suitable facilities are available from the one or more available facilities Annex (s) (n - 1) corresponding to step f) or g) depending on the minimum required Time and / or the maximum producible amount / throughput of the at least product is selected retrograde. Method according to one of claims 11 to 13, characterized in that by the control device ( 12 ) of the institution ( 14 ) data for the collection and delivery of customer order data, which in particular include information about orders and / or material and raw material quantities, semi-finished products, pre- or finished products and goods receipt as well as quality assurance data, are taken into account and processed for control engineering processes. Method according to one of claims 11 to 14, characterized in that by the control device ( 12 ) of the institution ( 22 ) Capacity parameters received for the acquisition and delivery of capacity parameters, in particular input parameters, preferably customer orders and related information about production orders, company parameters, preferably plants with associated operating data and capacities, and / or storage parameters, preferably intermediate and finished stock data, and / or filling parameters, preferably filling, packaging and commissioning, and / or material parameters, preferably materials, raw materials and supplies and semi-finished products, precursors and assemblies, and / or manufacturing parameters, preferably recipes and / or partial formulations, work instructions and dosing instructions, include and be taken into account for control engineering processes. Method according to one of claims 11 to 15, characterized in that by the control device ( 12 ) of the institution ( 24 ) for the collection and delivery of disturbance parameters, which in particular include information on plant malfunctions, defective production, material and personnel problems, resource shortages and changes to original data, changes in orders, order quantities or the transport situation are taken into account and processed for control processes. Method according to one of claims 11 to 16, characterized in that by the control device ( 12 ) in the event of disturbing parameters, all control-technical processes are adapted in real time taking into account the disturbing parameters and processed to an updated production. Method according to one of claims 11 to 17, characterized in that by the control device ( 12 ) internal or external shortage of raw materials or parts and / or general capacity bottlenecks or inadequate production capacities of individual plants, in particular plant parts, and / or missing personnel for operating, equipping and cleaning the plants, filling, packing and picking as well as transport and / or temporal preference of orders in the case of underutilized production capacities and / or blocked installations, in particular plant components used for production, and / or blocked work plans, recipes and / or sub-formulations, blocked raw materials, materials, intermediate products, intermediates and products or other manufacturing instructions, are processed. Method according to one of claims 11 to 18, characterized in that by the control device ( 12 ) in the case of internally or externally caused shortage of raw materials or parts and / or general capacity bottlenecks or insufficient production capacities of individual plants, in particular plant parts, and / or missing personnel for operating, equipping and cleaning the plants, filling, unpacking and order picking as well as transport and / or temporally bringing forward orders for underused production capacities and / or blocked installations, in particular plant components used for production and / or blocked work plans, parts lists, recipes and / or partial formulations, blocked raw materials, materials, intermediate products, intermediates and products or other manufacturing instructions, appropriate messages and notes are created. Method according to one of claims 11 to 19, characterized in that by the control device ( 12 ) calendrical data are taken into account and processed. Method according to one of claims 11 to 20, characterized in that by the control device ( 12 ) an arbitrary period of time is selected with associated orders, raw material, pre-product, intermediate or material deliveries. Method according to one of claims 11 to 21, characterized in that by the control device ( 12 ) in a multi-stage production, the optimal order of occupancy of the equipment is given, so that the entire Pro time for the production of the at least one product or the use of other resources, in particular the use of personnel, energy consumption and production costs are minimized. Method according to one of claims 11 to 22, characterized in that by the control device ( 12 ) Times of availability of facilities, intermediate storage and storage facilities for the at least one product, in particular for their maintenance and / or cleaning, are considered and processed. Method according to one of claims 11 to 23, characterized in that by the control device ( 12 ) individual plants, in particular plant parts, to a totality, in particular to groups summarized. Method according to one of claims 11 to 24, characterized in that by the control device ( 12 ) the shortest cycle times are selected from several manufacturing processes. Method according to one of claims 11 to 25, characterized in that by the control device ( 12 ) the minimum set-up and cleaning times of a product sequence are selected. Method according to one of claims 11 to 26, characterized in that by the control device ( 12 ) the number of shift times in which plants are operated are taken into account and determined. Method according to one of claims 11 to 27, characterized in that by the control device ( 12 ) are at least partially parameterized by shift times different maturities of individual plants. Method according to one of claims 11 to 28, characterized in that by the control device ( 12 ) the interruptibility of a process in the production is determined and processed. Method according to one of claims 11 to 29, characterized in that by the control device ( 12 ) the production is continued after an interruption, in particular due to a break of several hours, upon resumption of production without damage to the at least one product. Method according to one of claims 11 to 30, characterized in that by the control device ( 12 ) Interim storage locations and / or storage locations of materials, semi-finished products, intermediate products, intermediates and products in chronological order, based on the successive manufacturing processes, are taken into account and processed. Method according to one of claims 11 to 31, characterized in that by the control device ( 12 ) Precursors, intermediates and products with the same production and recipes and / or partial formulations or processes without splitting or combining parts of the precursors, intermediates and products are selected, with due to a traceability of batches materials and / or raw materials in the course of production clearly assigned become. Method according to one of claims 11 to 31, characterized in that by the control device ( 12 ) Pre-products, intermediates and products with the same production and the same formulations and / or sub-formulas or processes are divided or summarized in an optimal production quantity. Method according to one of claims 11 to 31 and 33, characterized in that by the control device ( 12 ) Intermediate products, intermediates and products during the filling, packaging, order picking or transport are split or grouped according to order. Method according to one of claims 11 to 31, 33 and 34, characterized in that by the control device ( 12 ) Parts from different orders with the same Merkma len, workflows, processes, recipes and / or sub-recipes are divided or summarized so that manufacturing capacity is optimally utilized and / or idle capacities are minimized. Method according to one of claims 11 to 31 and 33 to 35, characterized in that by the control device ( 12 ) the manufacturing orders are divided or summarized in such a way that the energy consumption for the orders to be processed in a period of time is minimized. Method according to one of claims 11 to 31 and 33 to 36, characterized in that by the control device ( 12 ) Manufacturing orders are divided or summarized in an arbitrary time period so that the production costs are minimized. Method according to one of claims 11 to 37, characterized in that by the control device ( 12 ) Quantities, minimum quantities and / or "bottoms" of intermediate products, Zwi products, and products that can not be produced economically on existing plants, in particular plant parts, recorded, selected and displayed or rejected or rejected. Method according to one of claims 11 to 38, characterized in that by the control device ( 12 ) Small quantities that are present as production orders are recorded, selected and displayed. Method according to one of claims 11 to 39, characterized in that by the control device ( 12 ) "frozen zones", in particular an ongoing production process as an input for a subsequent production process and / or a new planning run, are considered and processed. Method according to one of claims 11 to 40, characterized in that by the control device ( 12 ) the intermediate storage facilities and storage facilities necessary for the intermediate storage and disposal of intermediate products, intermediate products and products, in particular their areas, volumes or capacities, are taken into account and processed. Method according to one of claims 11 to 41, characterized in that by the control device ( 12 ), the permissibility of storage, based on expiration dates or the like, specified and processed for the intermediate storage and final storage of intermediate products, intermediates and products. Method according to one of claims 11 to 42, characterized in that by the control device ( 12 ) generate and compare different variants of alternative production plans and / or indicate deviations from one another. Method according to one of claims 11 to 43, characterized in that by the control device ( 12 ) costs incurred in the production, based on the time period or the at least one product or the manufacturing order, are determined and used for the calculation of the marginal costs. Method according to one of claims 11 to 44, characterized in that by the control device ( 12 ) Customer order data and / or capacity parameters and / or disturbance parameters can be input manually and integrated into the control-technical processes and / or displayed. Method according to one of claims 11 to 45, characterized that the actual data and / or desired data of the manufacturing process of at least a product and / or results of control engineering processes evaluated and in a GANTT chart, bar chart, production plan, in particular with differently colored fields, or in list form being represented. Method according to one of claims 11 to 46, characterized in that by the control device ( 12 ) All information of the control engineering processes, in particular all customer order data, capacity and / or disturbance parameters, measurement or similar control values, stored, displayed and archived.